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Abstract:

An apparatus for grouping discrete laminar articles (hereinafter referred
to as articles) into batches of predetermined count includes a feed
conveyor, a left-hand screw and a right-hand screw combination
(hereinafter referred to as screws), a means for synchronizing and
automating starting and stopping rotation of the screws and a platform
assembly. The platform assembly is connected to the feed conveyor and
includes a hatch and a pusher mechanism. The feed conveyor supports
articles disposed thereon. The screws are disposed along edges of and at
either side of the feed conveyor and are adapted to rotate to facilitate
counting and pushing of the articles. The screws stop rotating and
thereby stop further pushing of the articles, when a predetermined count
of articles has been pushed. The pusher mechanism receives the
predetermined count of articles pushed by screws and moves them to the
hatch from where they are dropped into delivery line.

Claims:

1. An apparatus for grouping discrete laminar articles into batches of
predetermined count, said apparatus comprising: a feed conveyor adapted
to support and convey discrete laminar articles disposed thereon; a left
hand screw and a right hand screw disposed along edges of either side of
said feed conveyor; said left hand screw and said right hand screw
adapted to rotate to facilitate counting and pushing of said discrete
laminar articles, wherein said left hand screw and said right hand screw
are adapted to stop rotating and thereby stop further pushing said
discrete laminar articles, when a predetermined count of discrete laminar
articles have been pushed; a means for synchronizing and automating
starting and stopping of rotation of said left hand screw and said right
hand screw; and a platform assembly functionally connected to said feed
conveyor, said platform assembly comprising; a pusher mechanism adapted
to receive and move said predetermined count of discrete laminar articles
pushed by said left hand screw and said right hand screw; and a hatch
adapted to receive said predetermined count of discrete laminar articles
moved by said pusher mechanism and drop said predetermined count of
discrete laminar articles into a delivery line of a wrapping station.

2. The apparatus as claimed in claim 1, wherein said means for
synchronizing and automating starting and stopping rotation of said
screws is a servo-motor;

3. The apparatus as claimed in claim 1, wherein said means for
synchronizing and automating starting and stopping rotation of said
screws is controlled by a rotary encoder.

4. The apparatus as claimed in claim 3, wherein said rotary encoder is
adapted to send signals to means for synchronizing and automating
starting and stopping rotation of said screws to stop rotation of said
screws and accordingly stop further pushing of said discrete laminar
articles, when a predetermined count of discrete laminar articles have
been pushed from said feed conveyor to said pusher mechanism of said
platform assembly.

5. The apparatus as claimed in claim 3, wherein said rotary encoder is
adapted to send signals to said pusher mechanism to move said discrete
laminar articles held therein to said hatch.

6. A method for grouping discrete laminar articles into batches of
predetermined count, said method comprising: supporting and conveying
discrete laminar articles on a feed conveyor; pushing said discrete
laminar articles along said feed conveyor by rotating a left hand screw
and a right hand screw disposed along edges of either side of said feed
conveyor; stopping rotation of said left hand screw and said right hand
screw and accordingly stopping further pushing of said discrete laminar
articles, when a predetermined count of discrete laminar articles have
been pushed to a pusher mechanism of a platform assembly functionally
connected to said feed conveyor; synchronization and automation of
starting and stopping of rotation of said left hand screw and said right
hand screw; and moving said pre-determined count of discrete laminar
articles held by the pusher mechanism to a hatch of said platform
assembly. dropping said pre-determined count of discrete laminar articles
received by the hatch into a delivery line of a wrapping station.

7. The method as claimed in claim 6, wherein said method involve
controlling said means for synchronizing and automating starting and
stopping of rotation of said screws by using a rotary encoder.

8. The method as claimed in claim 6, wherein said rotary encoder is also
used for controlling said pusher mechanism that is adapted to move
towards said hatch, after receiving said pre-determined count of discrete
laminar articles.

Description:

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority under 35 U.S.C. §119 from
Indian Patent Application Number 1568/MUM/2009, filed on Jul. 2, 2009,
entitled, "A Method and an Apparatus for Grouping Discrete Laminar
Articles into Batches of Predetermined Count."

FIELD OF THE INVENTION

[0002] This invention relates to methods and apparatuses for handling
discrete laminar articles such as biscuits along production lines, more
particularly, the present invention relates to a method and apparatus for
forming batches of biscuits.

BACKGROUND OF THE INVENTION

[0003] Automated biscuit making process involves four basic stages namely
mixing, forming, baking and packing. Once mixing, forming and baking
operations are completed, the biscuits thus formed leave the baking oven
in a continuous flow, along one or a plurality of supply-lines/chutes,
with biscuits upstanding about edges thereof and abutted against one
another. For some types of biscuits and packaging, it is necessary to
create appropriate batches out of the biscuits traveling along the supply
line. Such batches or arrays consist of a predetermined number of
biscuits. After forming batches out of the biscuits traveling along the
supply line, these batches are delivered to a wrapping or boxing
mechanism to perform packaging thereof into separate packages.

[0004] Some prior-art methods and apparatuses for grouping discrete
laminar articles such as biscuits into batches of predetermined count are
known. The methods and apparatuses for forming such batches and
transferring such batches to the delivery lines are known to cause and
face considerable difficulties and inconveniences along the production
lines. For example, the thicknesses of the biscuits being manufactured by
the automated biscuit making process vary during the course of
production. Due to variation in the thickness of the biscuits, there is
every chance of miscount during formation of batches thereby, resulting
in batches of non-uniform sizes that is undesirable. Further, there is
every possibility of breakage or crushing of the biscuits along edges
thereof, due to shearing action between the biscuits and the apparatuses
used for forming batches and transferring the batches during handling of
such batches.

[0005] The existing methods and apparatuses overcome the difficulties
faced by the prior-art methods and apparatuses for grouping discrete
laminar articles such as biscuits into batches of predetermined count.
However, such existing equipment operates at low speed or takes up too
much space. Further, existing apparatuses used for forming batches of
biscuits and transferring the batches make use of pressure-less feeders
in order to restrain damage to the biscuits, while being handled by the
existing apparatuses. However, such pressures-less feeders are
complicated and expensive.

[0006] Accordingly, there is felt a need for a method and an apparatus for
grouping discrete laminar articles such as biscuits into batches of
predetermined count that overcomes the drawbacks associated with the
prior art as well as existing methods and apparatuses and that can be
effectively used in production lines.

OBJECTS OF THE INVENTION

[0007] An object of the present invention is to provide a method and
apparatus for precisely grouping discrete laminar articles such as
biscuits into batches of predetermined count.

[0008] Another object of the present invention is to provide a compact
apparatus for forming batches.

[0009] Still another object of the present invention is to provide an
apparatus for forming batches that is sturdy and stable in construction.

[0010] Another object of the present invention is to provide an apparatus
for rapidly forming batches of predetermined count.

[0011] Still another object of the present invention is to provide an
apparatus for forming batches that safely handles discrete laminar
articles such as biscuits without causing any damage or breakage thereof
while being handled along production lines.

[0012] Yet another object of the present invention is to provide a method
and an apparatus for forming batches of discrete laminar articles such as
biscuits of any size or shape.

[0013] Another object of the present invention is to provide a method and
an apparatus for forming batches that is adapted to control and
accurately maintain spacing between the batches.

[0014] Still another object of the present invention is to provide a
method and an apparatus for forming batches that increases productivity.

[0015] Another object of the present invention is to provide an apparatus
for forming batches that reduces work of process control and quality
control departments.

[0016] Still another object of the present invention is to provide an
apparatus for forming batches that reduces manual monitoring and
supervisory tasks.

[0017] Yet another object of the present invention is to provide an
apparatus for forming batches that reduces human intervention.

SUMMARY OF THE INVENTION

[0018] In accordance with the present invention there is provided an
apparatus for grouping discrete laminar articles such as biscuits into
batches of predetermined count. The apparatus includes a feed conveyor, a
left-hand screw, a right-hand screw, a means for synchronizing and
automating starting and stopping rotation of the left hand screw and the
right hand screw and a platform assembly. The platform assembly is
functionally connected to the feed conveyor and includes a hatch and a
pusher mechanism. The feed conveyor is adapted to support and convey
discrete laminar articles such as biscuits disposed thereon. The left
hand screw and the right hand screw are disposed along edges of either
side of the feed conveyor. The left hand screw and the right hand screw
are adapted to rotate to facilitate counting and pushing of the discrete
laminar articles such as biscuits. Further, the left hand screw and the
right hand screw are adapted to stop rotating and thereby stop further
pushing of the discrete laminar articles such as biscuits, when a
predetermined count of the discrete laminar articles have been pushed.
The apparatus further includes means for synchronizing and automating
starting and stopping of rotation of the left hand screw and the right
hand screw. The pusher mechanism of the platform assembly is adapted to
receive and move the predetermined count of discrete laminar articles
such as biscuits pushed by the left hand screw and the right hand screw
to the hatch. The hatch of the platform assembly is adapted to receive
the predetermined count of the discrete laminar articles moved by the
pusher mechanism, and drop the predetermined count of the discrete
laminar articles into a delivery line of a wrapping station.

[0019] In one embodiment of the present invention, the means for
synchronizing and automating starting and stopping rotation of the screws
is a servo-motor.

[0020] Typically, the means for synchronizing and automating starting and
stopping rotation of the screws is controlled by a rotary encoder.

[0021] Further, the rotary encoder is adapted to send signals to the means
for synchronizing and automating starting and stopping rotation of the
screws to stop the rotation of the screws and accordingly stop further
pushing of the discrete laminar articles such as biscuits, when a
predetermined count of the discrete laminar articles have been pushed
from the feed conveyor to the pusher mechanism of the platform assembly.

[0022] Furthermore, the rotary encoder is also adapted to send signals to
the pusher mechanism to move the discrete laminar articles held therein
to the hatch.

[0023] In another aspect of the present invention there is provided a
method for grouping discrete laminar articles such as biscuits into
batches of predetermined count. The method involves supporting and
conveying discrete laminar articles such as biscuits on a feed conveyor
and thereafter pushing the discrete laminar articles along the feed
conveyor by rotating a left hand screw and a right hand screw disposed
along edges of either side of the feed conveyor. The method further
involves stopping rotation of the left hand screw and the right hand
screw and accordingly stopping further pushing of the discrete laminar
articles, when a predetermined count of discrete laminar articles such as
biscuits have been pushed to a platform assembly functionally connected
to the feed conveyor. Furthermore, the method for grouping discrete
laminar articles such as biscuits into batches of predetermined count
also involves synchronization and automation of starting and stopping of
rotation of the left hand screw and the right hand screw. The method
further involves moving the pre-determined count of discrete laminar
articles held by the pusher mechanism to a hatch of the platform assembly
and dropping the predetermined count of discrete laminar articles
received by the hatch into a delivery line of a wrapping station.

[0024] Typically, the method involves controlling the means for
synchronizing and automating starting and stopping of rotation of the
screws by using a rotary encoder.

[0025] Furthermore, the rotary encoder is also used for controlling the
pusher mechanism that is adapted to move to said hatch, after receiving
said pre-determined count of discrete laminar articles.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[0026] The invention will now be described in relation to the accompanying
drawings, in which:

[0027] FIG. 1 illustrates a view of an apparatus used for grouping
discrete laminar articles such as biscuits into batches of pre-determined
count, with a pusher mechanism of the apparatus in a down-configuration
in accordance with one embodiment of the present invention;

[0028] FIG. 2 illustrates another view of the apparatus of FIG. 1, with
the pusher mechanism of the apparatus in an up-configuration;

[0029] FIG. 3(a) and FIG. 3(b) illustrates perspective views of a left
hand screw and a right hand screw; and

[0030] FIG. 4 illustrates an isometric view of the apparatus of FIG. 1
operating along a production line of discrete laminar articles such as
biscuits.

DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[0031] The present invention provides a method and an apparatus for
grouping discrete laminar articles such as biscuits into batches of
predetermined count (hereinafter referred to as method and apparatus
respectively). More specifically, the apparatus of the present invention
is adapted to precisely count the discrete laminar articles such as
biscuits before forming batches there-from and transferring the batches
to a delivery line of a wrapping station. Further, the apparatus of the
present invention is adapted to simultaneously carry-out counting,
transferring and packaging of the discrete laminar articles, thereby
making the process of packaging the discrete laminar articles into
separate batches quicker and convenient. Furthermore, the apparatus of
the present invention ensures safe handling of the discrete laminar
articles, while being counted, transferred and packaged.

[0032] Referring to FIG. 1 and FIG. 2, the apparatus for grouping discrete
laminar articles such as biscuits into batches of predetermined count,
(hereinafter referred to as apparatus 100) includes a feed conveyor 12, a
right hand screw 16, a left hand screw 18, a left hand shaft 20, a right
hand shaft 22, a servo motor 24, a platform assembly 26. The platform
assembly includes a pusher mechanism 14, a hatch 28 and a striker plate
32 (not shown in FIG. 1 and FIG. 2).

[0033] The apparatus 100 of the present invention may be used for pushing
discrete laminar articles along a feed conveyor 12 and grouping together
a pre-determined count of the discrete laminar articles to form batches
there-from. For example, the apparatus of the present invention may be
used for moving together a predetermined count of discrete laminar
articles such as biscuits, pieces of cake, bread-slices or the like to
the hatch 28, from where the predetermined count of the discrete laminar
articles may be dropped to a delivery line of a wrapping station for
packaging the discrete laminar articles and forming a batch there-from.
However, the present invention is not limited to be used in a particular
production line for any particular discrete laminar article.

[0034] In accordance with an embodiment of the present invention, the feed
conveyor 12 is adapted to support a plurality of discrete laminar
articles such as biscuits 30 disposed thereon, wherein each of the
discrete laminar articles are standing on an edge thereof and is abutting
against an adjacent discrete laminar article.

[0035] The left hand screw 18 and the right hand screw 16 are located on
either side of the feed conveyor 12 and are disposed along edges thereof
as shown in the FIG. 1 and FIG. 2. Further, the left hand screw 18 and
the right hand screw 16 are adapted to rotate to facilitate counting and
pushing of the discrete laminar articles such as biscuits 30 along a
length of the feed conveyor 12. The axis of rotation of the left hand
screw 18 and the right hand screw 16 are parallel to the movement of the
discrete laminar articles 30 along the length of the feed conveyor 12.
More specifically, the right hand screw 16 is connected to the left hand
shaft 20 which typically rotates in clockwise direction and the left hand
screw 18 is connected to the right hand shaft 22 which typically rotates
in anticlockwise direction, thereby providing inward flow of the discrete
laminar articles 30 along the feed conveyor 12 and towards a receiving
face of the pusher mechanism 14 of the platform assembly 26 that is in a
down configuration as shown in FIG. 1. Further, the left hand screw 18
and the right hand screw 16 are adapted to stop rotating and thereby stop
pushing the discrete laminar articles such as biscuits 30 along a length
of the feed conveyor 12, when a pre-determined count of discrete laminar
articles forming a batch has been pushed to the receiving face of the
pusher mechanism 14 of the platform 26.

[0036] FIG. 3(a) and FIG. 3(b) of the accompanying drawings illustrates
perspective views of the left hand screw 18 and the right hand screw 16.
The adjacent crests 16(a) and 16(b) of the threads provided on the right
hand screw 16 and the adjacent crests 18(a) and 18(b) of the threads
provided on the left hand screw 18 are respectively adapted to
accommodate a lower edge portion and an upper edge portion of a discrete
laminar article belonging to the batch. The space between the adjacent
crests 16(a) and 16(b) of the threads provided on the right hand screw 16
is referred to as pitch 16(c). The space between the adjacent crests
18(a) and 18(b) of the threads provided on the left hand screw 18 is
referred to as pitch 18(c). During the release of a pre-determined count
of discrete laminar articles i.e. the batch to the receiving face of the
pusher mechanism 14 of the platform 26 (not shown in FIG. 3(a) and FIG.
3(b)), each of the discrete laminar articles belonging to the batch is
held between adjacent crests of the threads on the right hand screw 16
and the left hand screw 18.

[0037] Again referring to FIG. 1 and FIG. 2, the left hand shaft 20 and
the right hand shaft 22 are controlled by the servo-motor 24. The
servo-motor 24 is in turn controlled by a rotary encoder (not shown in
the FIG. 1 and FIG. 2) based on rpm of the left hand shaft 20 and the
right hand shaft 22. When the predetermined count of discrete laminar
articles such as biscuits, i.e. a batch of biscuits accumulates in the
pusher mechanism 14 of the platform assembly 26, the rotary encoder sends
signals to the servo-motor 24 which stop the rotation of the screws 16
and 18 and sends another signal to the pusher mechanism 14 which pushes
the batch of discrete laminar articles such as biscuits received thereby
to the hatch 28. The pushing of the batches of the discrete laminar
articles by the pusher mechanism 14 and the starting and stopping
operation of the right hand screw 16 and the left hand screw 18 by the
servo motor 24 is synchronized and automated.

[0038] FIG. 1-FIG. 2 of the accompanying drawings illustrate different
views of the apparatus 100 corresponding to different operational
configurations of the pusher mechanism 14. More specifically, the FIG. 1
illustrates a view of the apparatus 100, wherein the pusher mechanism 14
is in a down-configuration, whereas FIG. 2 illustrates another view of
the apparatus 100, wherein the pusher mechanism 14 is in an
up-configuration. In the down configuration of the pusher mechanism 14,
the receiving face of the pusher mechanism 14 is in line with the feed
conveyor 12 to facilitate receiving of a batch of discrete laminar
articles such as biscuits pushed by the left hand screw 18 and right hand
screw 16 combination disposed along either side of the feed conveyor 12.
Once the batch of the discrete laminar articles is received in the pusher
mechanism 14, the pusher mechanism 14 moves to the up-configuration to
facilitate transfer of the discrete laminar articles received thereby to
the hatch 28.

[0039] FIG. 4 illustrates an isometric view of the apparatus 100 operating
along a production line of discrete laminar articles such as biscuits. As
the pusher mechanism 14 carrying the batch of the discrete laminar
articles approaches the hatch 28, the discrete laminar articles from the
batch strike a striker plate 32 that is disposed adjacent to the hatch
28. The discrete laminar articles from the batch align themselves while
being in between the striker plate 32 and the pusher mechanism 14 and
thereafter rebound from the striker plate 32 without getting deformed to
drop through the hatch 28. The aligned articles leaving the hatch 28 are
dropped to a delivery line 34 of a wrapping station, where the aligned
articles are packaged to form the batch.

[0040] The method for precisely grouping discrete laminar articles such as
biscuits 30 into batches of predetermined count involves receiving
articles on the feed conveyor 12 from baking oven. The discrete laminar
articles such as biscuits 30 are picked up by the threads of the left
hand screw 18 and right hand screw 16 disposed at the edge of the feed
conveyor 12 and pushed forward on to the platform 26. The passage of the
discrete laminar articles through the screws 18 and 16, before the
discrete laminar articles 30 leave the feed conveyor 12 facilitate in
precisely counting the discrete laminar articles 30 by means of the
rotary encoder. When predetermined count of discrete laminar articles
accumulates in a batch, the pusher mechanism 14 pushes the batch to the
hatch 28 of the platform assembly 26, from where the batch is dropped to
delivery line 34 of wrapping station.

Technical Advancements and Economic Significance

[0041] The present invention provides a method and apparatus for precisely
grouping discrete laminar articles such as biscuits into batches of
predetermined count. The apparatus for forming batches is adapted to form
batches of uniform count. The apparatus for forming batches is of a
compact construction and accordingly is easy to handle and transport.
Further, the apparatus for forming batches is sturdy and stable in
construction. Furthermore, the apparatus for forming batches rapidly
forms batches of predetermined count. Still further, the apparatus for
forming batches gently handles discrete laminar articles such as biscuits
without causing any damage or breakage thereof while being handled.
Further, the apparatus for forming batches is adapted to handle discrete
laminar articles such as biscuits of different sizes. Still further, the
apparatus for forming batches is adapted to control and accurately
maintain spacing between the batches. Further, the apparatus for forming
batches is adapted to increases productivity. Furthermore, the apparatus
for forming batches reduces work of process control and quality control
departments and reduces manual monitoring and supervisory tasks. Still
further, the apparatus for forming batches reduces human intervention.
Furthermore, screws of different shapes and pitch may be used for
handling various types of discrete laminar articles.

[0042] While considerable emphasis has been placed herein on the
particular features of the preferred embodiment and the improvisation
with regards to it, it will be appreciated that various modifications can
be made in the preferred embodiment without departing from the principles
of the invention. These and other modifications in the nature of the
invention will be apparent to those skilled in the art from the
disclosure herein, whereby it is to be distinctly understood that the
foregoing descriptive matter is to be interpreted merely as illustrative
of the invention and not as a limitation.

Patent applications by Vijay Chauhan, Mumbai IN

Patent applications in class With means controlling the interrelated operation of plural sections

Patent applications in all subclasses With means controlling the interrelated operation of plural sections